iNOXPA ASPIR User manual

Type
User manual
INSTALLATION, SERVICE AND MAINTENANCE INSTRUCTIONS
SIDE CHANNEL PUMP
ASPIR
Original Instructions
01.400.30.09EN
(A) 2021/11
01.400.32.0005
4 INOXPA S.A.U. · 01.400.30.09EN · (A) 2021/11
1. Table of Contents
1. Table of Contents
2. Generalities
2.1. Instructions manual ....................................................................................................................................... 5
2.2. Compliance with the instructions .................................................................................................................. 5
2.3. Warranty ........................................................................................................................................................ 5
3. Safety
3.1. Warning symbols........................................................................................................................................... 6
3.2. General safety instructions ........................................................................................................................... 6
4. General Information
4.1. Description .................................................................................................................................................... 7
4.2. Operating principle ........................................................................................................................................ 7
4.3. Application ..................................................................................................................................................... 7
5. Installation
5.1. Reception of the pump .................................................................................................................................. 8
5.2. Identification of the pump .............................................................................................................................. 8
5.3. Transport and storage ................................................................................................................................... 9
5.4. Location ......................................................................................................................................................... 9
5.5. Pipes ........................................................................................................................................................... 10
5.6. Mechanical seal with quench ...................................................................................................................... 10
5.7. Electrical installation ................................................................................................................................... 11
6. Start-up
6.1. Checks before starting the pump ................................................................................................................ 12
6.2. Checks when starting the pump .................................................................................................................. 12
7. Troubleshooting
8. Maintenance
8.1. General considerations ............................................................................................................................... 15
8.2. Check the mechanical seal ......................................................................................................................... 15
8.3. Maintenance of the seals ............................................................................................................................ 15
8.4. Tightening torque ........................................................................................................................................ 15
8.5. Storage ........................................................................................................................................................ 16
8.6. Cleaning ...................................................................................................................................................... 16
8.7. Disassembly and assembly of the pump .................................................................................................... 17
9. Technical Specifications
9.1. Weight with whroud and legs ...................................................................................................................... 20
9.2. Weight without whroud and without legs .................................................................................................... 21
9.3. Dimensions with whroud and legs .............................................................................................................. 21
9.4. Dimensions without whroud and without legs ............................................................................................. 22
9.5. Exploded drawing of ASPIR pump.............................................................................................................. 23
9.6. Parts list of ASPIR pump ............................................................................................................................ 24
9.7. Mechanical seal with quench ...................................................................................................................... 25
Generalities
INOXPA S.A.U. · 01.400.30.09EN · (A) 2021/11 5
2. Generalities
2.1. INSTRUCTIONS MANUAL
This manual contains information regarding the reception, installation, operation, assembly, disassembly and
maintenance of the ASPIR pumps.
Carefully read the instruction prior to starting the pump, familiarize yourself with the installation, operation and
correct use of the pump and strictly follow the instructions. These instructions should be kept in a safe location
near the installation area.
The information published in the instruction manual is based on updated data.
INOXPA reserves the right to modify this instruction manual without prior notice.
2.2. COMPLIANCE WITH THE INSTRUCTIONS
Not following the instructions may impose a risk for the operators, the environment and the machine, and may
result in the loss of the right to claim damages.
This non-compliance may result in the following risks:
failure of important machine/plant functions,
failure of specific maintenance and repair procedures,
possible electrical, mechanical and chemical hazards,
risk to the environment due to the type of substances released.
2.3. WARRANTY
The conditions of the warranty are specified in the General Sales Conditions that have been delivered at the
time of placing your order.
The machine may not undergo any modification without prior approval from the manufacturer.
For your safety, only use original spare parts and accessories.
The usage of other parts will relieve the manufacturer of any liability.
Changing the service conditions can only be carried out with prior written authorization from
INOXPA.
The non-compliance of the prescribed indications in this manual means misuse of this gear on the technical side
and the personal safety and this, exempt INOXPA of all responsibility in case of accidents and personal injuries
and/or property damage. Also, excluded from the warranty all breakdowns caused by improper use of the gear.
Please do not hesitate to contact us in case of doubts or if further explanations are required regarding
specific data (adjustments, assembly, disassembly, etc.)
Safety
6 INOXPA S.A.U. · 01.400.30.09EN · (A) 2021/11
3. Safety
3.1. WARNING SYMBOLS
Safety hazard for people in general and/or for equipment
Electric hazard
Important instruction for the protection of the equipment and its functions
3.2. GENERAL SAFETY INSTRUCTIONS
Read the instruction manual carefully before installing and starting the pump. Contact INOXPA in
case of doubt.
3.2.1. During the installation
The Technical Specifications of chapter 9 should always be observed.
Never start the pump before connecting it to the lines.
Do not operate the pump if the discharge casing is not fitted.
Check for proper specifications of the motors, especially it its working conditions create an
explosions hazard.
During the installations, all the electric work should be carried out by authorized personnel.
3.2.2. During operation
The Technical Specifications of chapter 9 should always be observed. Under no circumstances can
the specified limit values be exceeded.
NEVER touch the pump or the pipework during operation if the pump is being used for transferring
hot liquids or during cleaning.
The pump contains moving parts. Never place your fingers inside the pump during operation.
NEVER operate with the suction and discharge valves closed.
NEVER spray water directly on the electrical motor. The standard motor protection is IP-55:
protection against dust and water spray.
3.2.3. During maintenance
The Technical Specifications of chapter 9 shall always be observed.
NEVER disassemble the pump until the pipes have been emptied. Remember that liquid will
remain inside the pump’s pump casing (if does not have a purge). Bear in mind that the pumped
liquid may be hazardous or extremely hot. Consult the regulations in effect in each country for
these cases.
Do not leave loose parts on the floor.
ALWAYS disconnect the electrical power to the pumps prior to carrying out any maintenance.
Remove the fuses and disconnect the cable from the motor’s terminals.
All electrical work must be carried out by authorized personnel
ATTENTION
General Information
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4. General Information
4.1. DESCRIPTION
The ASPIR pump has a compact construction, monoblock and vertical aspiration and impulse.
The ASPIR pump is made of a cold-formed stainless steel discharge casing, suction casing, diffuser and lantern
built by stainless steel investment casting, star-shaped fixed impeller and an external mechanical seal that
prevents any contact of the spring with the product.
The standard IEC motor of type IM B35 is protected by a stainless steel shroud and provided with height
adjustable hygienic designed legs in stainless steel too.
4.2. OPERATING PRINCIPLE
The impeller is housed between the suction casing and the diffuser and it rotates in conjunction with the pump
shaft. This arrangement, together with the rotation of the impeller and the arrangement of the side channel,
creates a negative pressure inside the suction casing, which generates the suction force of the pump. At the
same time, the fluid receives energy in the form of kinetic energy and pressure energy, and this impels it
through the discharge casing.
4.3. APPLICATION
ASPIR pump is a sanitary side-channel self-priming pump suitable for use in the food-processing,
pharmaceutical and chemical industries.
It is specially designed for pumping products containing air or gas, and it can also be used for negative suction
with prior priming as well as in filtration equipment. It can be used to pump wine, oil, syrups, volatile products
such as alcohol, acetone and other solvents or products at temperatures close to the boiling point.
However, the main use of this pump is for CIP return.
For each type of pump, the hydraulic performance is given by the choice of impeller diameters and speeds. The
characteristic curves also show the power and NPSH requirements. The intended use of the pump is defined by
its characteristic curve and operating limits provided in the 9. Technical Specifications.
The range of application for each type of pump is limited. The pump was selected for a given set of
pumping conditions when the order was placed. Misuse of the pump or its use beyond the
operating limits may be dangerous or cause permanent damage to the equipment. INOXPA shall
not be liable for any damage resulting from the incompleteness of the information provided by the
purchaser (nature of the fluid, rpm, etc.).
ATTENTION
Installation
8 INOXPA S.A.U. · 01.400.30.09EN · (A) 2021/11
5. Installation
5.1. RECEPTION OF THE PUMP
INOXPA cannot be held responsible for the damage sustained by the equipment during transport
or unpacking. Please visually check that the packaging is not damaged.
The pump package includes the following documents:
shipping documents,
installation, service and maintenance instructions manual,
instructions and service manual of the motor
1
.
Unpack the pump and check the following:
The suction and discharge connections of the pump, removing any rest of packaging materials,
The pump and the motor are not damaged,
If the equipment is not in good condition and/or any part is missing, the carrier should report accordingly
as soon as possible.
5.2. IDENTIFICATION OF THE PUMP
Each pump has a nameplate with the basic data required to identify the model.
1
If the pump has been supplied with a motor from INOXPA
Serial number
01.011.32.0016
01.400.32.0006
Installation
INOXPA S.A.U. · 01.400.30.09EN · (A) 2021/11 9
5.3. TRANSPORT AND STORAGE
The ASPIR pumps are often too heavy to be stored manually.
Use an appropriate means of transport.
Use the points which are indicated in the drawing for lifting the pump.
Only authorized personnel should transport the pump.
Do not work or walk under the heavy loads.
Lift the pump as indicated below:
Always use two support points placed as far apart as possible.
Always remove the motor shroud before hoisting
Secure the supports so that they will not move.
See chapter 9. Technical Specifications to consult dimensions and weights.
During the transport, disassembly or assembly of the pump, there is a risk of loss of stability and
that the pump could fall down and cause damages to the operators. Make sure that the pump is
properly supported.
5.4. LOCATION
Place the pump in position that allows enough space around it to provide access to the pump as well as to the
motor. See chapter 9. Technical Specifications to consult dimensions and weights.
Place the pump on a flat and lever surface.
Install the pump so as to allow proper ventilation.
If the pump is installed outdoors, it should be covered by a roof. Its location should allow easy
access for inspection or maintenance operations.
01.400.32.0007
Installation
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5.4.1. Excessive temperatures
Depending on the fluid to be pumped, high temperatures can be reached inside and around the pump.
Over 68ºC the operator should take protective measures and place warning notices advising of the
danger which exists if the pump is touched.
The type of protection selected should not isolate the pump entirely. It should allow for the bearings
to be cooled more efficiently and for the bearings to be lubricated.
5.5. PIPES
As a general rule, install the suction and discharge lines in straight sections, with the minimum possible
number of elbows and fittings in order to reduce any pressure losses that may be caused by friction.
Make sure that the pump’s ports are properly aligned with the pipework and have a diameter similar to that
of the pump connections.
Place the pump as close as possible to the suction tank and whenever possible below the liquid level, or
even below the tank level in order to achieve the largest possible static head for suction.
Install support brackets for the lines as close as possible to the pump’s suction and discharge ports in order
to avoid vibrations and stress on the pump.
5.5.1. Shut-off valves
The pump may be isolated for maintenance. To accomplish this, shut-off valves must be installed and
connected to the pump’s suction and discharge connections.
These valves must ALWAYS be open during operation of the pump.
5.6. MECHANICAL SEAL WITH QUENCH
Models with mechanical seal with quench may require the inlet and outlet connection to the cooling liquid.
See the limits of water consumption and pressure from the cooling circuit in chapter 9. Technical
Specifications.
01.400.32.0008
Installation
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5.7. ELECTRICAL INSTALLATION
Only qualified personnel can connect the electric motors.
Take the necessary measures to prevent damage to cables and connections.
Electrical equipment, terminals and components of the control systems may still carry current when
they are disconnected. Contacting them may impose a hazard to operators or cause irreparable
material damage.
Before handling the pump, make sure that the motor is stopped.
Connect the motor in accordance with the instructions supplied by the motor manufacturer, in
accordance with the current national legislation and in compliance with EN 60204-1.
Check the direction of rotation (see the signalling label on the pump).
Start and stop the pump motor momentarily. Make sure that the direction of rotation is correct. If the
pump rotates in the wrong direction it could cause serious damage.
See indicator label on the pump.
ALWAYS check the direction of rotation of the motor with liquid inside the pump.
01.400.32.0009
Start-up
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6. Start-up
Before starting the pump, carefully read the instructions in chapter 5. Installation.
Carefully read chapter 9. Technical Specifications. INOXPA will not be liable for improper use of
the equipment.
NEVER touch the pump or the lines if hot liquids are being pumped.
6.1. CHECKS BEFORE STARTING THE PUMP
Completely open the shut-off valves on the suction and discharge lines.
If liquid does not flow towards the pump, fill it with the liquid to be pumped.
The pump must never turn dry.
Check that the power supply matches the rating indicated on the motor plate.
Check that the direction of rotation of motor is the right one.
If the pump has the flow by-pass option, when it suction from a level below of the pump level, the by-
pass will be closed why it will not suction.
6.2. CHECKS WHEN STARTING THE PUMP
Check that the pump is not making any strange noises.
Check if the absolute inlet pressure is sufficient to prevent cavitation in the pump. See the curve to
determine the minimum pressure required above steam pressure (NPSHr).
Control the discharge pressure.
Check for leaks in the sealing areas.
Shut-off valves on the suction pipe must not be used to regulate the flow. All shut-off valves must
be fully open during operation.
Control the motor consumption to prevent an electrical overload.
Reduce the flow rate and the electrical power consumed by the motor:
by regulating the pump’s discharge flow,
by decreasing the motor speed,
the pumps with an internal by-pass flow, open it (see performance curve with open/closed by-pass).
Start-up
INOXPA S.A.U. · 01.400.30.09EN · (A) 2021/11 13
Use special protection when the sound pressure in the operation area exceeds 85 dB(A).
If the pump has not an incorporated a pressure by-pass you should mount a relief valve or any
other device that limits the pressure to 11,7 bar.
01.400.32.0010
Troubleshooting
14 INOXPA S.A.U. · 01.400.30.09EN · (A) 2021/11
7. Troubleshooting
The following table provides solutions to problems that might arise during the operation of the pump. The pump
is assumed to have been properly installed and be suitable for the relevant application.
Please contact INOXPA if technical assistance is required.
Motor overload
The pump does not provide enough flow or pressure
No pressure on the discharge side
Uneven discharge flow / pressure
Noise and vibration
The pump gets clogged
Overheated pump
Excessive wear
The mechanical seal leaks
PROBABLE CAUSES
SOLUTIONS
Wrong direction of rotation
Reverse the direction of rotation
NPSH is not high enough
Raise the suction tank
Lower the pump
Reduce the vapour pressure
Widen the diameter of the suction pipe
Shorten and simplify the suction line
Pump not drained
Drain or fill
Cavitation
Increase suction pressure
Air is suctioned by the pump
Check the suction pipe and all its
connections
Clogged suction pipe
Check the suction pipe and all its
filters, if any
Discharge pressure too high
If necessary, reduce load losses, e.g.
by increasing the pipe diameter
Flow too high
Partially open the discharge valve.
Decrease speed.
Open the internal by-pass
Fluid viscosity too high
Reduce the viscosity, e.g. by heating
the fluid
Fluid temperature too high
Reduce the temperature by cooling
the fluid
Mechanical seal damaged or worn
out
Replace the seal
O-rings unsuitable for the fluid
Fit suitable O-rings. Consult the
manufacturer.
The impeller scrapes
Lower the temperature
Reduce the suction pressure
Adjust the impeller / cover play
Tension in the lines
Connect the pipes to the pump without
tension
Foreign matter in the liquid
Install a filter in the suction pipe
Mechanical seal spring tension Is too
low
Adjust as indicated in this manual
Maintenance
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8. Maintenance
8.1. GENERAL CONSIDERATIONS
This pump, just like any other machine, requires maintenance. The instructions contained in this manual cover
the identification and replacement of spare parts. The instructions are aimed at maintenance personnel and
those responsible for the supply of spare parts.
Carefully read chapter 9. Technical Specifications.
Maintenance work can only be carried out by qualified personnel that are trained and equipped
with the necessary resources to carrying out this work.
All parts or materials that are replaced must be properly disposed of/recycled in accordance with
the current directives applicable in each area.
ALWAYS disconnect the pump before beginning any maintenance work.
8.2. CHECK THE MECHANICAL SEAL
Periodically check that there are no leaks around the shaft. If leakage is detected through the mechanical seal,
replace it following the instructions in the chapter 8.7. Disassembly and assembly of the pump.
8.3. MAINTENANCE OF THE SEALS
SEALS REPLACEMENT
Preventive maintenance
Replace after twelve (12) months. We also recommend replacing the
gaskets during seal or pump shaft replacement.
Maintenance after a leak
Replace at the end of the process. If the impeller nut gasket fails, the
threaded hole on the impeller and the threads on the end shaft have to be
cleaned. Follow the instructions given in 8.6. Cleaning.
Scheduled maintenance
Regularly check that there are no leaks and that the pump is operating
correctly.
Keep a record of the pump.
Use statistics to plan inspections.
Lubrication
During assembly, use soapy water when fitting the different gaskets to
allow them to slide better.
The period between each preventive maintenance service will vary depending on the operating condition of the
pump: temperatures, flow, number of operating hours, cleaning solutions used, etc.
8.4. TIGHTENING TORQUE
If not stated otherwise, the torques listed in the following table should be applied on the nuts and bolts of this
pump.
Size
Nm
lbf·ft
M6
10
7
M8
21
16
M10
42
31
M12
74
55
M16
112
83
Maintenance
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8.5. STORAGE
Before being stored the pump must be completely emptied of liquids. Avoid, as far as possible, the exposure of
the parts to excessively damp atmospheres.
8.6. CLEANING
The use of aggressive cleaning products such as caustic soda and nitric acid may give raise to skin
burns.
Use rubber gloves during cleaning procedures.
Always use protective goggles.
8.6.1. Automatic CIP (clean-in-place)
If the pump is installed in a system with a CIP process, it is not necessary to disassemble the pump.
If the automatic cleaning process is not provided, proceed to disassemble the pump as indicated in the chapter
8.7. Disassembly and assembly of the pump.
Check the concentration of the cleaning solutions. Incorrect concentrations may lead to the
deterioration of the pump seals.
To remove any traces of cleaning products ALWAYS perform a final rinse with clean water at the end of the
cleaning process.
Cleaning solutions for CIP processes
Only use clear water (chlorine-free) to mix with the cleaning agents:
a. Alkaline solution: 1 % by weight of caustic soda (NaOH) a 70ºC (150ºF)
1 kg NaOH + 100 l H2O = cleaning solution
or
2,2 l NaOH of 33% + 100 l H2O = cleaning solution
b. Acid solution: 0,5% by weight of nitric acid (HNO3) a 70ºC (150ºF)
0,7 l HNO3 of 53% + 100 l H2O = cleaning solution
Maintenance
INOXPA S.A.U. · 01.400.30.09EN · (A) 2021/11 17
8.7. DISASSEMBLY AND ASSEMBLY OF THE PUMP
The assembly and disassembly of the pumps should be done by qualified personnel. Make sure that the
personnel read carefully this instruction manual and, in particular, those instructions which refer to the work they
will perform.
Incorrect assembly or disassembly may cause damage in the pump’s operation and lead to high
repair costs and a long period of down time.
INOXPA is not responsible for accidents or damages cause by a failure to comply with the
instructions in this manual.
Preparation
Provide for a clean working environment so some parts, including the mechanical seal, require very careful
handling and others have close tolerances.
Check that the parts which are used are not damaged during transport. When doing this, you need to inspect
the adjustment edge, the butted faces, the tight fit, burrs, etc.
After each disassembly, carefully clean the parts and check for any damage. Replace all damaged parts.
Tools
Use the proper tools for assembly and disassembly operations. Use them correctly.
Cleaning
Before disassembling the pump, clean it outside and inside.
NEVER clean the pump by hand when it is running.
8.7.1. Disassembly of the pump and single mechanical seal
1. Remove the clamping ring (15) and disassemble the
disassemble the discharge casing (01A).
2. Check the condition of the O-ring (80) on the suction
casing and replace if damaged
3. Ensure that the O-ring is placed is not twisted during
the assembly.
4. Remove the diffuser (16). May be that when the
discharge casing (01A) is extracted, the diffuser
leaves together with it.
5. Loosen the countersunk screw (50) that fixes the
impeller.
6. Remove the washer (35) and the impeller (02). If is
necessary use an extractor at impeller threaded
holes.
7. Remove the screws (50A) and remove the protector
(47A).
8. Remove the screws (52B) and the suction casing
(01).
9. Manually remove the stationary part of the seal (08)
which is located in the suction casing (01).
10. The rotating part is located free on the shaft (05).
Slide it by the shaft.
11. Check the sealing surfaces and O-rings from the
mechanical seal (08) are not damaged.
01.400.32.0012
01.400.32.0011
Maintenance
18 INOXPA S.A.U. · 01.400.30.09EN · (A) 2021/11
8.7.2. Assembly of the pump and the single mechanical seal
1. Fit the stationary part of the seal (08) on the suction casing (01) manually.
2. Slide the rotating part of the mechanical seal (08) in the shaft.
3. Mount the suction casing (01), securing it by the screws (52B) and washers (53A).
4. Check the A dimension is according with the next table. Is the dimension is not correct, loosen the studs
(55) and place the shaft according A dimension.
5. Mount the impeller (02) in the pump shaft (05). If there is a key (61), depending the model, enter it
previously.
6. Enter the impeller (02) and the washer (35) and fix all by the countersunk screw (50).
7. Mount the diffuser (16) with two O-rings (80A) located.
8. Finally, position the discharge cover (01A) fixing it with the clamping ring (15).
9. Rotate manually the pump shaft (05) to check that the impeller (02) turns soft and without rubbing with
suction casing (01) or diffuser (16).
When installing the new seal, use soapy water when fitting the different parts and gaskets to allow
them to slide better. Apply to the stationary as well as the rotating parts.
8.7.3. Motor change
1. Firstly, proceed according the steps previously
explained.
2. Remove the splash ring (82).
3. Loosen the allen studs (55) and remove the shaft
(05).
4. If the pump contains a shroud, remove the screws
(50B) that join both parts from the shroud (14) and
the screws with fix it to legs (07). After that remove
the shroud (14).
5. Remove the hexagonal screws (52) and washers
(53) and then extract the lantern (04) and the frontal
part of shroud.
6. Finally, remove the legs (07) taking out the screws
(52), nut (54) and washers (53,53A)
.
8.7.4. Mechanical seal with quench
Disassembly
1. Proceed according the chapter 8.6.1. Disassembly of the pump and single mechanical seal.
2. At the point 9, remove carefully the suction casing (01) that has located the lip seal (88).
Assembly
1. Fit the stationary part of the seal (08) on the suction casing (01) manually.
2. Assembly the lip seal (88) in the suction casing (01).
Model
A 0,2 [mm]
A 50
3
A 80
6,67
A 150
3
A 200
5,9
01.400.32.0013
01.400.32.0013
Maintenance
INOXPA S.A.U. · 01.400.30.09EN · (A) 2021/11 19
3. Slide the rotating part of the mechanical seal (08) in the shaft.
4. Check that chrome of the shaft surface (05) to contact with lip seal (88) is in good conditions. If not,
replace the shaft with a new one. Fix the shaft according the table of chapter 8.6.1. Disassembly of the
pump and single mechanical seal.
5. Assembly the suction cover (01) carefully to avoid damaging the lip seal with the rotating part of
mechanical seal and then fix the screws (52B) and washers (53A).
When installing the new seal and lip seal, use soapy water when fitting the different parts and seals
to allow them to slide better.
Technical Specifications
20 INOXPA S.A.U. · 01.400.30.09EN · (A) 2021/11
9. Technical Specifications
Maximum operating pressure 1.000 kPa (10 bar)
Temperature range -10ºC to 120ºC
Maximum speed 1.500 rpm (50 Hz)
1.800 rpm (60 Hz)
Noise level 61 to 80 dB
Materials
Parts in contact with the product 1.4404 (AISI 316L)
Other stainless steel parts 1.4301 (AISI 304)
Seals in contact with the product EPDM (standard)
FPM (other materials available upon request)
Exterior surface finish matt
Interior surface finish bright polished except the electropolished impeller
Mechanical seal
Type of seal: single inside seal
Material of stationary part graphite (C) standard
silicon carbide (SiC)
Material of rotating part silicon carbide (SiC) standard
Seal material EPDM standard
FPM
Water consumption (quench mechanical seal) 0,25 to 0,6 l/min
Pressure (quench mechanical seal) from atmospheric to 100 kPa (1 bar)
Motor
Type three-phase asynchronous motor, IEC B35 type, 4 poles,
IP55 protection, class F insulation
Power 0,75 to 15 kW
Voltage and frequency 220-240 V Δ / 380-420 V Υ, ≤ 4 kW
380-420 V Δ / 660-690 V Υ, ≥ 5,5 kW
Use special protection when the sound pressure in the operation area exceeds 85 dB(A)
9.1. WEIGHT WITH WHROUD AND LEGS
Weight (kg)
IEC
80
100
112
132
160
kW
0,75
2,2
3
4
5.5
7.5
11
15
A 50
28
A 80
57
61
67
A 150
66
86
97
A 200
161
184
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iNOXPA ASPIR User manual

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User manual

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